Phosphorus-containing caprolactone monomers for synthesis of flame retardant polycaprolactones

ABSTRACT

A process of forming a flame retardant monomer includes forming a hydroxyl-functionalized caprolactone molecule, and reacting the hydroxyl-functionalized with a phosphorus-containing flame retardant molecule to form a flame retardant-functionalized caprolactone monomer. A flame retardant monomer includes at least one moiety derived from a hydroxyl-functionalized caprolactone molecule and at least one phosphorus-containing flame retardant moiety. A flame retardant polymer includes at least two flame retardant monomer repeat units, each flame retardant monomer repeat unit including at least one moiety derived from a hydroxyl-functionalized caprolactone molecule and at least one phosphorus-containing flame retardant moiety.

BACKGROUND

Plastics are typically derived from a finite and dwindling supply ofpetrochemicals, resulting in price fluctuations and supply chaininstability. Replacing non-renewable petroleum-based polymers withpolymers derived from renewable resources may be desirable. However,there may be limited alternatives to petroleum-based polymers in certaincontexts. To illustrate, particular plastics performance standards maybe specified by a standards body or by a regulatory agency. In somecases, alternatives to petroleum-based polymers may be limited as aresult of challenges associated with satisfying particular plasticsperformance standards.

SUMMARY

Various embodiments are directed to a process of forming a flameretardant monomer. The process includes forming ahydroxyl-functionalized caprolactone molecule, and reacting thehydroxyl-functionalized with a phosphorus-containing flame retardantmolecule to form a flame retardant-functionalized caprolactone monomer.The process can also include reacting the monomer with anunfunctionalized caprolactone monomer to form a flame retardantpolycaprolactone copolymer. In some embodiments, thephosphorus-containing flame retardant molecule includes a cross-linkingmoiety, such as an allyl group, an epoxide group, or a furan group.These cross-linking moieties can be attached by forming thephosphorus-containing flame retardant molecule from allylic alcohol,glycidol or furfuryl alcohol, respectively. In other embodiments, thefuran group can be attached by forming the phosphorus-containing flameretardant molecule from 2-(chloromethyl)furan.

Additional embodiments are directed to flame retardant monomer, whichincludes at least one moiety derived from a hydroxyl-functionalizedcaprolactone molecule and at least one phosphorus-containing flameretardant moiety. The phosphorus-containing flame retardant moiety caninclude an allyl group, an epoxide group, at least one phenyl group, ora thioether linking group.

Further embodiments are directed to a flame retardant polymer. The flameretardant polymer includes at least two flame retardant monomer repeatunits, and each flame retardant monomer repeat unit includes at leastone moiety derived from a hydroxyl-functionalized caprolactone moleculeand at least one phosphorus-containing flame retardant moiety. Thepolymer can be a copolymer or a homopolymer. The polymer can alsoinclude at least one unfunctionalized caprolactone repeat unit. Thepolymer can be formed in a polymerization reaction catalyzed by tin(II)octanoate. Additionally, the polymer can include cross-linking bonds.

The foregoing and other objects, features and advantages of theinvention will be apparent from the following more particulardescriptions of exemplary embodiments of the invention as illustrated inthe accompanying drawings wherein like reference numbers generallyrepresent like parts of exemplary embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a chemical reaction diagram showing a process of forming afirst flame retardant (FR)-functionalized caprolactone molecule using aphosphorus-based FR molecule and polymerizing the firstFR-functionalized caprolactone molecule to form a first FRpolycaprolactone, according to one embodiment.

FIG. 2 is a chemical reaction diagram showing a process of forming asecond FR-functionalized caprolactone molecule using a phosphorus-basedFR molecule and polymerizing the second FR-functionalized caprolactonemolecule to form a second FR polycaprolactone, according to oneembodiment.

FIG. 3 is a chemical reaction diagram showing a process of forming afirst FR polycaprolactone copolymer from a mixture of monomers thatincludes a non-functionalized caprolactone monomer and the firstFR-functionalized caprolactone of FIG. 1, according to one embodiment.

FIG. 4 is a chemical reaction diagram showing a process of forming asecond FR polycaprolactone copolymer from a mixture of anon-functionalized caprolactone monomer and the second FR-functionalizedcaprolactone of FIG. 2, according to one embodiment.

FIG. 5 is a chemical reaction diagram showing a process of forming athird FR-functionalized caprolactone using a phosphorus-based FRmolecule and polymerizing the third FR-functionalized caprolactone toform a third FR polycaprolactone, according to one embodiment.

FIG. 6 is a chemical reaction diagram showing a process of forming afourth FR-functionalized caprolactone using a phosphorus-based FRmolecule and polymerizing the fourth FR-functionalized caprolactone toform a fourth FR polycaprolactone, according to one embodiment.

FIG. 7 is a chemical reaction diagram showing a process of forming athird FR polycaprolactone copolymer from a mixture of anon-functionalized caprolactone monomer and the third FR-functionalizedcaprolactone of FIG. 5, according to one embodiment.

FIG. 8 is a chemical reaction diagram showing a process of forming afourth FR polycaprolactone copolymer from a mixture of anon-functionalized caprolactone monomer and the fourth FR-functionalizedcaprolactone of FIG. 6, according to one embodiment.

FIGS. 9A and 9B are chemical reaction diagrams showing alternativeembodiments of processes of forming a first phosphorus-based FR moleculefor forming a FR-functionalized caprolactone molecule.

FIG. 10 is a chemical reaction diagram showing a process of forming aFR-functionalized caprolactone molecule with one or more cross-linkersfrom a caprolactone molecule that is functionalized with aphosphate-based FR molecule that includes an allyl group, according toone embodiment.

FIGS. 11A and 11B are chemical reaction diagrams showing alternativeembodiments of processes of forming a second phosphorus-based FRmolecule for forming a FR-functionalized caprolactone molecule.

FIG. 12 is a chemical reaction diagram showing a process of forming aFR-functionalized caprolactone molecule with one or more cross-linkersfrom a caprolactone molecule that is functionalized with aphosphonate-based FR molecule that includes an allyl group, according toone embodiment.

FIG. 13 is a chemical reaction diagram showing a process of forming athird phosphorus-based FR molecule for forming a FR-functionalizedcaprolactone molecule, according to one embodiment.

FIGS. 14A and 14B are chemical reaction diagrams showing alternativeembodiments of processes of forming a fourth phosphorus-based FRmolecule for forming a FR-functionalized caprolactone molecule.

FIGS. 15A and 15B are chemical reaction diagrams showing alternativeembodiments of processes of forming a fifth phosphorus-based FR moleculefor forming a FR-functionalized caprolactone molecule.

FIGS. 16A and 16B are chemical reaction diagrams showing alternativeembodiments of processes of forming a sixth phosphorus-based FR moleculefor forming a FR-functionalized caprolactone molecule.

FIG. 17 is a flow diagram showing a particular embodiment of a processof forming a flame retardant polycaprolactone.

FIG. 18 is a flow diagram showing a particular embodiment of a processof forming a flame retardant polycaprolactone.

DETAILED DESCRIPTION

The present disclosure describes phosphorus-containing caprolactonemonomers and flame retardant (FR) polycaprolactones formed from thephosphorus-containing caprolactone monomers. The flame retardantfunctionalized (FR-functionalized) caprolactone monomers of the presentdisclosure may be formed from one or more phosphorus-based FR moleculesthat include at least one phosphorus moiety to impart flame retardancycharacteristics and at least one cross-linking moiety (e.g., forsubsequent cross-linking of the FR polycaprolactones into a variety ofdifferent polymeric materials). Examples of cross-linking moietiesinclude allyl groups, epoxide groups, and furan groups. In some cases,thiol-ene “Click” chemistry may be used to convert the allyl group(s) tohydroxyl, amine, carboxylic acid, or ester cross-linker(s). In the caseof furans, the furan moieties represent diene groups that may be usedfor (reversibly) cross-linking the FR polycaprolactones of the presentdisclosure to a renewable/non-renewable polymeric material.

Referring to FIG. 1, a chemical reaction diagram 100 illustrates aprocess of forming a first FR-functionalized caprolactone molecule usinga phosphorus-based FR molecule and polymerizing the firstFR-functionalized caprolactone molecule to form a first FRpolycaprolactone, according to one embodiment. As further describedherein, the phosphorus-based FR molecule may correspond to one of thephosphorus-based FR molecules synthesized according to one of theprocesses described herein with respect to FIGS. 9A/9B, 11A/B, 13,14A/14B, 15A/B, and 16A/B. As further described herein, thephosphorus-based FR molecules that may be utilized to impart flameretardancy characteristics to a caprolactone molecule may also includeone or more cross-linking groups.

FIG. 1 illustrates that the first FR-functionalized caprolactonemolecule may be synthesized from a caprolactone molecule via a diolintermediate. In the first chemical reaction depicted at the top of FIG.1, a carbon-carbon double bond is added to the caprolactone molecule toform an intermediate molecule. The second chemical reaction illustratesthat a 2,3-hydroxyl-caprolactone molecule may be synthesized from theintermediate molecule via an Upjohn dihydroxylation involving catalyticosmium tetroxide.

In the third chemical reaction (depicted at the bottom of FIG. 1), thehydroxyl groups of the 2,3-hydroxyl-caprolactone molecule arefunctionalized with one of the phosphorus-based flame retardantmolecules described herein with catalytic dimethylaminopyridine (DMAP)to form the first FR-functionalized caprolactone molecule. The fourthchemical reaction illustrates that the first FR-functionalizedcaprolactone molecule is then polymerized using catalytic tin(II)octanoate to form a first FR polycaprolactone (with cross-linkers, notshown in FIG. 1).

As a prophetic example, referring to the first chemical reactiondepicted at the top of FIG. 1, one equivalent of n-Butyllithium (n-BuLi)may be added dropwise to anhydrous tetrahydrofuran (THF) anddiisopropylamine (1.2 equiv.) in dry THF under nitrogen at −78° C. for15 minutes. c-Caprolactone (1 equiv.) in dry THF may be added dropwise,and the solution may be stirred at −78° C. for 15 minutes. Oneequivalent of phenylselenenyl bromide (PhSeBr) in dry THF may be addedrapidly between −78° C. and −60° C., and the solution may be stirred at−78° C. for 15 min. Water (20 mL) may be added, and the THF may beevaporated in vacuo. The resulting residue may be extracted with diethylether (4×). The combined organic solvents may be washed with water (4×),dried (MgSO₄), filtered, and evaporated in vacuo. The residue in ethermay be kept at −20° C. overnight to give the phenylselenenyl lactone(14.1 g) as crystals. The mother liquors may be chromatographed onsilica gel, eluting with dichloromethane to give more phenylselenenyllactone. Hydrogen peroxide (30%, 1.3 equiv.) may be added dropwise withstirring to the phenylselenenyl lactone (1 equiv.) in THF at 25° C.After the addition is complete, the temperature may be maintainedbetween 30° C. and 33° C. for 2.5 hours. The resulting solution may beevaporated in vacuo, and the residue may be chromatographed on silicagel, eluting with ether-light petroleum (bp: 30-40° C.) (1:1) to givethe “caprolactone-diene” product depicted on the right side of thechemical reaction arrow, which may be further purified by distillation.

As a prophetic example, referring to the second chemical reactiondepicted at the top of FIG. 1, to a stirred solution of the“caprolactone-diene” (1 equiv.) in a solution of acetone/water (8:1) maybe added (2 equiv.) N-Methylmorpholine N-oxide (NMO) and a 2.5% solutionof osmium tetroxide (OsO₄) in tert-butanol (t-BuOH) (5 mol % of OsO₄),and the mixture may be stirred overnight at room temperature. Thereaction may be quenched with a saturated solution of Na₂S₂O₃, and maybe stirred for one hour and transferred in a separation funnel. Theaqueous layer may be extracted with ethyl acetate, the combined organiclayers dried over Na₂SO₄ and the solvent removed under reduced pressure.The crude product may be purified by recrystallization or columnchromatography.

As a prophetic example, referring to the third chemical reactiondepicted at the bottom of FIG. 1, to a solution of the“dihydroxycaprolactone” (1 equiv.) and a phosphorus-based FR molecule(>2 equiv.), such as diphenyl chlorophosphate, in anhydrousdichloromethane (DCM) or THF at 0° C., may be added a solution oftrimethylamine (NEt₃) and/DMAP (>2 equiv.) in anhydrous DCM or THF,dropwise. The reaction may be heated to reflux and stirred for up to 24hours. The reaction may be poured into a saturated solution of ammoniumchloride and stirred for one hour and transferred in a separationfunnel. The aqueous layer may be extracted with ethyl acetate, thecombined organic layers dried over Na₂SO₄, and the solvent removed underreduced pressure. The crude product may be purified by recrystallizationor column chromatography.

As a prophetic example, referring to the fourth chemical reactiondepicted at the bottom of FIG. 1, the FR-functionalized caprolactone anda catalyst such as tin(II) octanoate, Sn(Oct)₂ (0.1-1 mol %), may beadded to a reaction vessel, which may contain a solvent such as DCM.After a period of up to 24 hours, the melt or solution may be addeddirectly to hexanes or methanol, dropwise or all in one portion, toprecipitate the polymer, which may be collected by filtration and driedin a vacuum oven at >60° C. until complete removal of volatiles(determined by thermogravimetric analysis).

Thus, FIG. 1 illustrates an example of a process of forming a firstFR-functionalized caprolactone molecule using a phosphorus-based FRmolecule and polymerizing the first FR-functionalized caprolactonemolecule to form a first FR polycaprolactone. As further describedherein, the phosphorus-based molecule that is used to form the firstFR-functionalized caprolactone molecule may also include one or morecross-linking functional groups for subsequent cross-linking of thefirst FR polycaprolactone.

Referring to FIG. 2, a chemical reaction diagram 200 illustrates aprocess of forming a second FR-functionalized caprolactone moleculeusing a phosphorus-based FR molecule and polymerizing the secondFR-functionalized caprolactone molecule to form a second FRpolycaprolactone, according to one embodiment. As further describedherein, the phosphorus-based FR molecule may correspond to one of thephosphorus-based FR molecules synthesized according to one of theprocesses described herein with respect to FIGS. 9A/9B, 11A/B, 13,14A/14B, 15A/B, and 16A/B. As further described herein, thephosphorus-based FR molecules that may be utilized to impart flameretardancy characteristics to a caprolactone molecule may also includeone or more cross-linking groups.

FIG. 2 illustrates that the second FR-functionalized caprolactonemolecule may be synthesized from a caprolactone molecule via a polyolintermediate (that includes four hydroxyl groups). In the chemicalreactions depicted at the top of FIG. 2, two carbon-carbon double bondsare added to the caprolactone molecule. In the chemical reactionsdepicted in the middle of FIG. 2, a 2,3,4,5-hydroxyl-caprolactonemolecule may be synthesized via an Upjohn dihydroxylation involvingcatalytic osmium tetroxide.

In the chemical reactions depicted at the bottom of FIG. 2, the fourhydroxyl groups of the 2,3,4,5-hydroxyl-caprolactone molecule arefunctionalized with one of the phosphorus-based flame retardantmolecules described herein with catalytic DMAP to form the secondFR-functionalized caprolactone molecule. The second FR-functionalizedcaprolactone molecule is then polymerized using catalytic tin(II)octanoate to form a second FR polycaprolactone (with cross-linkers, notshown in FIG. 2).

The first chemical reaction depicted at the top of FIG. 2 may beperformed in a similar manner to the first chemical reaction depicted atthe top of FIG. 1. With respect to the second chemical reaction depictedat the top of FIG. 2, as a prophetic example, to a stirred anhydroussolution of the “caprolactone-diene” in a solution of either anhydrousDCM or benzene, may be added bromine dropwise. The solution may includea free radical initiator such as azobisisobutyronitrile (AIBN) orbenzoyl peroxide. The solution may be heated to reflux and/or placedunder UV radiation (hv) of approximately 254 nm. Upon completion, thereaction may be filtered or quenched with a sodium thiosulfate solution,and the layers may be separated. The organic layer may be rinsed withwater and brine and may be dried over MgSO₄. The solvent may be removedin vacuo, and the residue may be purified by recrystallization or columnchromatography.

As a prophetic example, referring to the third chemical reactiondepicted at the top of FIG. 2, to a stirred anhydrous solution of the“bromocaprolactone-diene” in a solution of either anhydrous DCM or THF,may be added a solution of NEt₃ in the same solvent, dropwise. Thesolution may be heated to reflux. Upon completion, the reaction may bequenched with a sodium thiosulfate solution, and the layers may beseparated. The organic layer may be rinsed with water and brine, and maybe dried over MgSO₄. The solvent may be removed in vacuo, and theresidue may be purified by recrystallization or column chromatography.

The fourth chemical reaction depicted in the middle of FIG. 2 may beperformed in a similar manner to the second chemical reaction depictedat the top of FIG. 1, except for doubling the number of equivalents toform a “tetrahydroxycaprolactone” rather than a “dihydroxycaprolactone”as in the example of FIG. 1. The fifth chemical reaction depicted in themiddle of FIG. 2 may be performed in a manner similar to the thirdchemical reaction depicted at the bottom of FIG. 1, except for doublingthe number of equivalents of the phosphorus-based FR molecule. The sixthchemical reaction depicted at the bottom of FIG. 2 may be performed in amanner similar to the fourth chemical reaction depicted at the bottom ofFIG. 1.

Thus, FIG. 2 illustrates an example of a process of forming a secondFR-functionalized caprolactone molecule using a phosphorus-based FRmolecule and polymerizing the second FR-functionalized caprolactonemolecule to form a second FR polycaprolactone. As further describedherein, the phosphorus-based molecule that is used to form the secondFR-functionalized caprolactone molecule may also include one or morecross-linking functional groups for subsequent cross-linking of thesecond FR polycaprolactone.

Referring to FIG. 3, a chemical reaction diagram 300 illustrates aprocess of forming a first FR polycaprolactone copolymer from a mixtureof monomers that includes a non-functionalized caprolactone monomer andthe first FR-functionalized caprolactone of FIG. 1, according to oneembodiment.

In FIG. 3, the integer m is used to designate a first portion of thefirst FR polycaprolactone copolymer that corresponds to theFR-functionalized caprolactone monomer. The integer n is used todesignate a second portion of the first FR polycaprolactone copolymerthat corresponds to the unfunctionalized caprolactone monomer. In theexample of FIG. 3, the FR-functionalized caprolactone monomer includestwo phosphorus-based flame retardant groups per molecule. Accordingly,the first portion of the FR polycaprolactone copolymer of FIG. 3includes two phosphorus-based flame retardant groups per repeat unit.Adjusting the relative amounts of the monomers in the mixture enablescontrol over the flame retardant and physical/thermal properties of theresulting copolymer.

As a prophetic example, an unfunctionalized caprolactone, theFR-functionalized caprolactone containing two FR groups, and a catalystsuch as tin (II) octanoate, Sn(Oct)₂ (0.1-1 mol %), may be added to areaction vessel, which may contain a solvent such as DCM. After a periodof up to 24 hours, the melt or solution may be added directly to hexanesor methanol, dropwise or all in one portion, to precipitate the polymer,which may be collected by filtration and dried in a vacuum oven at >60°C. until complete removal of volatiles (determined by thermogravimetricanalysis).

Thus, FIG. 3 illustrates an example of a process of forming a FRpolycaprolactone copolymer from a mixture of monomers that includes anon-functionalized caprolactone monomer and a FR-functionalizedcaprolactone monomer. As further described herein, the phosphorus-basedmolecule that is used to form the FR-functionalized caprolactone monomermay also include one or more cross-linking functional groups forcross-linking of the FR polycaprolactone copolymer.

Referring to FIG. 4, a chemical reaction diagram 400 illustrates aprocess of forming a second FR polycaprolactone copolymer from a mixtureof monomers that includes an unfunctionalized caprolactone monomer andthe second FR-functionalized caprolactone of FIG. 2, according to oneembodiment.

In FIG. 4, the integer m is used to designate a first portion of thesecond FR polycaprolactone copolymer that corresponds to theFR-functionalized caprolactone monomer. The integer n is used todesignate a second portion of the second FR polycaprolactone copolymerthat corresponds to the unfunctionalized caprolactone monomer. In theexample of FIG. 4, the FR-functionalized caprolactone monomer includesfour phosphorus-based flame retardant groups per molecule. Accordingly,the first portion of the FR polycaprolactone copolymer of FIG. 4includes four phosphorus-based flame retardant groups per repeat unit.Adjusting the relative amounts of the monomers in the mixture enablescontrol over the flame retardant and physical/thermal properties of theresulting copolymer.

As a prophetic example, an unfunctionalized caprolactone, theFR-functionalized caprolactone containing four FR groups, and a catalystsuch as tin (II) octanoate, Sn(Oct)₂ (0.1-1 mol %), may be added to areaction vessel, which may contain a solvent such as DCM. After a periodof up to 24 hours, the melt or solution may be added directly to hexanesor methanol, dropwise or all in one portion, to precipitate the polymer,which may be collected by filtration and dried in a vacuum oven at >60°C. until complete removal of volatiles (determined by thermogravimetricanalysis).

Thus, FIG. 4 illustrates an example of a process of forming a FRpolycaprolactone copolymer from a mixture of monomers that includes anunfunctionalized caprolactone monomer and a FR-functionalizedcaprolactone monomer. As further described herein, the phosphorus-basedmolecule that is used to form the FR-functionalized caprolactone monomermay also include one or more cross-linking functional groups forcross-linking of the FR polycaprolactone copolymer.

Referring to FIG. 5, a chemical reaction diagram 500 illustrates aprocess of forming a third FR-functionalized caprolactone molecule usinga phosphorus-based FR molecule and polymerizing the thirdFR-functionalized caprolactone molecule to form a third FRpolycaprolactone, according to one embodiment. As further describedherein, the phosphorus-based FR molecule may correspond to one of thephosphorus-based FR molecules synthesized according to one of theprocesses described herein with respect to FIGS. 9A/9B, 11A/B, 13,14A/14B, 15A/B, and 16A/B. As further described herein, thephosphorus-based FR molecules that may be utilized to impart flameretardancy characteristics to a caprolactone molecule may also includeone or more cross-linking groups.

FIG. 5 illustrates that the third FR-functionalized caprolactonemolecule may be synthesized from a caprolactone molecule via an epoxide(oxirane) intermediate. In the first chemical reaction depicted at thetop of FIG. 5, a carbon-carbon double bond is added to the caprolactonemolecule to form an intermediate molecule. The second chemical reactionillustrates that a 2-oxiranyl-caprolactone molecule may be synthesizedfrom the intermediate molecule using hydrogen peroxide. The fourthchemical reaction illustrates that the epoxide rings are then opened viaa reductive ring-opening using sodium borohydride and phenyl diselenideto form 3-hydroxyl-caprolactone.

In the fifth chemical reaction (depicted at the bottom of FIG. 5), thehydroxyl group of the 3-hydroxyl-caprolactone molecule arefunctionalized with one of the phosphorus-based flame retardantmolecules described herein with catalytic DMAP to form the thirdFR-functionalized caprolactone molecule. The sixth chemical reactionillustrates that the third FR-functionalized caprolactone molecule isthen polymerized using catalytic tin(II) octanoate to form a third FRpolycaprolactone (with cross-linkers, not shown in FIG. 5).

The first chemical reaction depicted at the top of FIG. 5 may beperformed in a similar manner to the first chemical reaction depicted atthe top of FIG. 1. With respect to the second chemical reaction depictedat the top of FIG. 5, as a prophetic example, to a solution of the“caprolactone-diene” (1 equiv.) in MeOH-THF (3:1) may be added aqueous35% H₂O₂ (>0.5 equiv.) and 6M aqueous NaOH (1.25 equiv.) at 0° C. Afterbeing stirred at the same temperature for 2 h, H₂O, ether, and 2Maqueous HCl may be added to the reaction mixture. The organic phase maybe separated, and the aqueous phase may be extracted with ether (2×).The combined organic extracts may be washed with brine, dried overanhydrous Na₂SO₄, and concentrated in vacuo. The residue may be purifiedby silica gel column chromatography.

As a prophetic example, referring to the third chemical reactiondepicted at the top of FIG. 5, to a stirred solution of (1.5 equiv.)diphenyl diselenide, Ph₂Se₂, in isopropanol may be added NaBH₄ (3.0equiv.) portion-wise at room temperature, and after a few minutes AcOH(70% v/v of isopropanol) may be added at the same temperature. After 5minutes, the mixture may be cooled to 0° C., and a solution of the“epoxy caprolactone” (1.0 equiv.) in isopropanol may be added dropwiseto the mixture. Stirring may continue for 30 min at the sametemperature. The mixture may be diluted with EtOAc, and the organiclayer may be washed with brine and dried with MgSO₄. After evaporationof the solvent under reduced pressure, the residue may be purified bycolumn chromatography.

The fourth chemical reaction depicted at the bottom of FIG. 5 may beperformed in a similar manner to the third chemical reaction depicted atthe bottom of FIG. 1, except for halving the number of equivalents ofthe phosphorus-based FR molecule. The fifth chemical reaction depictedat the bottom of FIG. 5 may be performed in a manner similar to thefourth chemical reaction depicted at the bottom of FIG. 1.

Thus, FIG. 5 illustrates an example of a process of forming a thirdFR-functionalized caprolactone molecule using a phosphorus-based FRmolecule and polymerizing the third FR-functionalized caprolactonemolecule to form a third FR polycaprolactone. As further describedherein, the phosphorus-based molecule that is used to form the thirdFR-functionalized caprolactone molecule may also include one or morecross-linking functional groups for subsequent cross-linking of thethird FR polycaprolactone.

Referring to FIG. 6, a chemical reaction diagram 600 illustrates aprocess of forming a fourth FR-functionalized caprolactone moleculeusing a phosphorus-based FR molecule and polymerizing the fourthFR-functionalized caprolactone molecule to form a fourth FRpolycaprolactone, according to one embodiment. As further describedherein, the phosphorus-based FR molecule may correspond to one of thephosphorus-based FR molecules synthesized according to one of theprocesses described herein with respect to FIGS. 9A/9B, 11A/B, 13,14A/14B, 15A/B, and 16A/B. As further described herein, thephosphorus-based FR molecules that may be utilized to impart flameretardancy characteristics to a caprolactone molecule may also includeone or more cross-linking groups. The chemical reactions depicted inFIG. 6 may be performed in a similar manner to the chemical reactionspreviously described herein with respect to FIG. 5, except for doublingthe number of equivalents of the appropriate reagents.

FIG. 6 illustrates that the fourth FR-functionalized caprolactonemolecule may be synthesized from a caprolactone molecule via an epoxide(oxirane) intermediate. For ease of illustration purposes, the firstmolecule depicted at the top left of FIG. 6 corresponds to the moleculeof FIG. 2 having two carbon-carbon double bonds that are added to thecaprolactone molecule. In the first chemical reaction depicted at thetop of FIG. 6, a 2,3,4,5-dioxiranyl-caprolactone molecule may besynthesized using hydrogen peroxide. FIG. 6 further illustrates that theepoxide rings are then opened via a reductive ring-opening using sodiumborohydride and phenyl diselenide. The reaction conditions may result ina mixture of stereochemistry to form a mixture of3,4-hydroxyl-caprolactone and 3,5-hydroxyl-caprolactone.

In the chemical reactions depicted at the bottom of FIG. 6, the hydroxylgroups of the 3,4-hydroxyl-caprolactone and 3,5-hydroxyl-caprolactonemolecules are functionalized with one of the phosphorus-based flameretardant molecules described herein with catalytic DMAP to form thefourth FR-functionalized caprolactone molecule. FIG. 6 furtherillustrates that the fourth FR-functionalized caprolactone molecule isthen polymerized using catalytic tin(II) octanoate to form a fourth FRpolycaprolactone (with cross-linkers, not shown in FIG. 6).

Thus, FIG. 6 illustrates an example of a process of forming a fourthFR-functionalized caprolactone molecule using a phosphorus-based FRmolecule and polymerizing the fourth FR-functionalized caprolactonemolecule to form a fourth FR polycaprolactone. As further describedherein, the phosphorus-based molecule that is used to form the fourthFR-functionalized caprolactone molecule may also include one or morecross-linking functional groups for subsequent cross-linking of thefourth FR polycaprolactone.

Referring to FIG. 7, a chemical reaction diagram 700 illustrates aprocess of forming a third FR polycaprolactone copolymer from a mixtureof monomers that includes an unfunctionalized caprolactone monomer andthe third FR-functionalized caprolactone monomer of FIG. 5, according toone embodiment. The chemical reaction depicted in FIG. 7 may beperformed in a similar manner to the co-polymerization reactionpreviously described herein with respect to FIGS. 3 and 4.

In FIG. 7, the integer m is used to designate a first portion of thethird FR polycaprolactone copolymer that corresponds to theFR-functionalized caprolactone monomer. The integer n is used todesignate a second portion of the first FR polycaprolactone copolymerthat corresponds to the unfunctionalized caprolactone monomer. In theexample of FIG. 7, the FR-functionalized caprolactone monomer includesone phosphorus-based flame retardant group per molecule. Accordingly,the first portion of the FR polycaprolactone copolymer of FIG. 7includes one phosphorus-based flame retardant group per repeat unit.Adjusting the relative amounts of the monomers in the mixture enablescontrol over the flame retardant and physical/thermal properties of theresulting copolymer.

Thus, FIG. 7 illustrates an example of a process of forming a FRpolycaprolactone copolymer from a mixture of monomers that includes anunfunctionalized caprolactone monomer and a FR-functionalizedcaprolactone monomer. As further described herein, the phosphorus-basedmolecule that is used to form the FR-functionalized caprolactone monomermay also include one or more cross-linking functional groups forcross-linking of the FR polycaprolactone copolymer.

Referring to FIG. 8, a chemical reaction diagram 800 illustrates aprocess of forming a fourth FR polycaprolactone copolymer from a mixtureof monomers that includes an unfunctionalized caprolactone monomer andthe fourth FR-functionalized caprolactone of FIG. 6, according to oneembodiment. The chemical reaction depicted in FIG. 8 may be performed ina similar manner to the co-polymerization reaction previously describedherein with respect to FIGS. 3 and 4.

In FIG. 8, the integer m is used to designate a first portion of thefirst FR polycaprolactone copolymer that corresponds to theFR-functionalized caprolactone monomer. The integer n is used todesignate a second portion of the first FR polycaprolactone copolymerthat corresponds to the unfunctionalized caprolactone monomer. In theexample of FIG. 8, the FR-functionalized caprolactone monomer includestwo phosphorus-based flame retardant groups per molecule. Accordingly,the first portion of the FR polycaprolactone copolymer of FIG. 8includes two phosphorus-based flame retardant groups per repeat unit.Adjusting the relative amounts of the monomers in the mixture enablescontrol over the flame retardant and physical/thermal properties of theresulting copolymer.

Thus, FIG. 8 illustrates an example of a process of forming a FRpolycaprolactone copolymer from a mixture of monomers that includes anunfunctionalized caprolactone monomer and a FR-functionalizedcaprolactone monomer. As further described herein, the phosphorus-basedmolecule that is used to form the FR-functionalized caprolactone monomermay also include one or more cross-linking functional groups forcross-linking of the FR polycaprolactone copolymer.

FIGS. 9A and 9B are chemical reaction diagrams showing alternativeembodiments of processes of forming a first phosphorus-based FR moleculefor formation of a FR-functionalized caprolactone molecule. The firstphosphorus-based FR molecule depicted in FIGS. 9A and 9B represents anexample of a phosphate-based FR molecule that is functionalized with onemoiety for cross-linking and one chloride for further bonding with acaprolactone molecule that is functionalized with one or more hydroxylgroups, as previously described herein with respect to FIGS. 1, 2, 5,and 6.

Referring to FIG. 9A, a first chemical reaction diagram 900 illustratesa first embodiment of a process of forming the first phosphorus-based FRmolecule. In FIG. 9A, the first phosphorus-based FR molecule is formedvia a one-step process via reaction of an alcohol (ROH) with phenyldichlorophosphate via careful addition and stoichiometric control. FIG.9A illustrates that the alcohol may be either allylic alcohol orglycidol. In the case of allylic alcohol, the R group of the firstphosphorus-based FR molecule includes an allyl functional group that maybe utilized as a polymeric cross-linker. In the case of glycidol, the Rgroup of the first phosphorus-based FR molecule includes a terminalepoxide functional group that may be utilized as a cross-linker.

As a prophetic example, to a stirred solution that may include allylicalcohol or glycidol (1.0 eq.) and triethylamine (2.0 eq.) in anhydrousTHF, phenyl dichlorophosphate (1.3 eq.) may be added dropwise at 0° C.,and the reaction mixture may be stirred at ambient temperature for 2hours or the reaction mixture may be heated up to reflux (60-65° C.) foran extended reaction time (4 hours). The reaction mixture may be cooledto ambient temperature and filtered to remove the triethylaminehydrochloride salt. The solvents of the filtrate may be removed invacuo, and the product may be purified by fractional distillation.

Referring to FIG. 9B, a second chemical reaction diagram 910 illustratesan alternative embodiment of a process of forming the firstphosphorus-based FR molecule. The first chemical reaction depicted inFIG. 9B illustrates that the alcohol (ROH) may be reacted with titanium(IV) isopropoxide and phosphonic acid diphenyl ester via apseudo-esterification to form an intermediate molecule. The secondchemical reaction depicted in FIG. 9B illustrates that the intermediatemolecule may be reacted with thionyl chloride to form the firstphosphorus-based FR molecule. When the alcohol is allylic alcohol, the Rgroup of the first phosphorus-based FR molecule includes an allylfunctional group that may be utilized as a polymeric cross-linker. Whenthe alcohol is glycidol, the R group of the first phosphorus-based FRmolecule includes a terminal epoxide functional group that may beutilized as a cross-linker.

As a prophetic example, diaryl phosphite (5.5 mmol) may be added to asolution of titanium (IV) isopropoxide, Ti(OPr)₄ (11 mmol), in allylicalcohol or glycidol (excess). This solution may be diluted with benzene.The reaction mixture may be heated to 40° C. until completion. Themixture may be poured into water, extracted with CH₂Cl₂ (3×), dried overMgSO₄, and solvent and volatile components may be removed in vacuo. Theproducts may be purified by fractional distillation orrecrystallization. The product from the first step (1.0 eq.), in dryacetonitrile (MeCN), toluene, or dichloromethane (DCM), may be added toa solution of trichloroisocyanuric acid (0.33 eq.), N-chlorosuccinimide(1.0 eq.), or tert-butyl hypochlorite (1.0 eq.) in the same solvent atroom temperature, under an N₂ atmosphere. Upon formation of aprecipitate, the reaction may be stirred at room temperature for anadditional 2 hours. Upon completion of the reaction, as determined by³¹P NMR, the reaction mixture may be passed through a 0.45 μm Whatmansyringe filter and concentrated under vacuum. Next, thionyl chloride(SOCl₂) may be dissolved in a suitable solvent, such as carbontetrachloride (CCl₄), and the chemical reaction may be performed from 0°C. to room temperature.

Thus, FIGS. 9A and 9B illustrate alternative processes of forming aphosphate-based FR molecule that is functionalized with one moiety forcross-linking and one chloride for further bonding with a caprolactonemolecule that is functionalized with one or more hydroxyl groups. WhileFIGS. 9A and 9B illustrate an example in which the phosphate-based FRmolecule includes a phenyl group, it will be appreciated that the phenylgroup may be substituted by ethyl, methyl, propyl, or isopropyl groups,among other alternatives.

Referring to FIG. 10, a chemical reaction diagram 1000 illustrates anexample of a process of forming a FR-functionalized caprolactonemolecule with one or more cross-linkers from a caprolactone moleculethat is functionalized with a phosphate-based FR molecule that includesan allyl group, according to one embodiment.

In FIG. 10, the letter Y is used to represent a hydroxyl group, an aminegroup, a carboxylic acid group, or an ester group. FIG. 10 illustratesthat the allyl-functionalized caprolactone molecule (formed according toone of the processes described herein with respect to FIGS. 9A and 9B)may be chemically reacted with a molecule that includes a thiol groupand the Y group via thiol-ene “Click” chemistry to form aFR-functionalized caprolactone molecule that includes a hydroxylcross-linker, an amine cross-linker, a carboxylic acid cross-linker, oran ester cross-linker.

As a prophetic example, the thiol compound may be mixed with thevinyl-functionalized FR-functionalized caprolactone. The mixture mayinclude a radical initiator, such as a Micheler's ketone, analpha-amino-ketone, an alpha-hydroxy-ketone, a benzyldimethyl ketal, orbenzophenone (among other alternatives). The reactants may be dissolvedin a solvent such as DCM, benzene, or carbon tetrachloride and reactedunder UV light at a time and temperature suitable to the includedradical initiators as appropriate for desired applications.

FIGS. 11A and 11B are chemical reaction diagrams showing alternativeembodiments of processes of forming a second phosphorus-based FRmolecule for formation of a FR-functionalized caprolactone molecule. Thesecond phosphorus-based FR molecule depicted in FIGS. 11A and 11Brepresents an example of a phosphonate-based FR molecule that isfunctionalized with one moiety for cross-linking and one chloride forfurther bonding with a caprolactone molecule that is functionalized withone or more hydroxyl groups, as previously described herein with respectto FIGS. 1, 2, 5, and 6.

Referring to FIG. 11A, a first chemical reaction diagram 1100illustrates a first embodiment of a process of forming the secondphosphorus-based FR molecule. In the first chemical reaction depicted inFIG. 11A, a chloride molecule (RCl) is chemically reacted withtriphenylphosphite to form a phosphonyl ester intermediate material. Inthe second chemical reaction depicted in FIG. 11A, the phosphonyl esterintermediate material is chemically reacted with phosphoruspentachloride to form the second phosphorus-based FR molecule. FIG. 11Aillustrates that the chloride may be either allyl chloride orepichlorohydrin. In the case of allyl chloride, the R group of thesecond phosphorus-based FR molecule includes an allyl functional groupthat may be utilized as a polymeric cross-linker. In the case ofepichlorohydrin, the R group of the second phosphorus-based FR moleculeincludes a terminal epoxide functional group that may be utilized as across-linker.

As a prophetic example, allyl chloride or epichlorohydrin (1 eq.) andtrialkyl phosphite, P(OR)₃, may be added to a reaction vessel. Thereaction vessel may include an organic solvent such as toluene, THF,ethanol, or DMF, and may also contain a compound such an alumina. Thereaction may be heated to reflux or up to 180° C. if done using neatconditions. The reaction mixture may also be irradiated by microwavesfor a short period to increase the reaction rate. The reaction may becooled to room temperature, and the excess trialkyl phosphite may beremoved in vacuo or it may be washed with DCM, and dried using CaCl₂prior to filtration and having the solvents removed in vacuo. Thephosphonate may be purified by fractional distillation. To a solution ofthe phosphonate product may be added PCl₅ (excess) at 0° C. under aninert atmosphere. The reaction may be performed in a solvent such asCCl₄. The mixture may be allowed to warm up to room temperature and maybe stirred for an additional day. The solvent may then be removed invacuo, and the residue may be distilled to give the product.

Referring to FIG. 11B, a second chemical reaction diagram 1110illustrates an alternative embodiment of a process of forming the secondphosphorus-based FR molecule. In the first chemical reaction depicted inFIG. 11B, a chloride molecule (RCl) is chemically reacted withtriphenylphosphite and quenched under aqueous basic conditions to form aphosphonyl ester intermediate material. In the second chemical reactiondepicted in FIG. 11B, the phosphonyl ester intermediate material ischemically reacted with thionyl chloride to form the secondphosphorus-based FR molecule. FIG. 11B illustrates that the chloride maybe either allyl chloride or epichlorohydrin. In the case of allylchloride, the R group of the second phosphorus-based FR moleculeincludes a terminal allyl functional group that may be utilized as apolymeric cross-linker. In the case of epichlorohydrin, the R group ofthe second phosphorus-based FR molecule includes a terminal epoxidefunctional group that may be utilized as a cross-linker.

As a prophetic example, an allyl phosphonate or oxirane phosphonate (1.0eq.) may be generated and quickly added to a solution of bromodimethylborane (1.0 eq.) in an organic solvent such as toluene. The reactionmixture may be warmed to room temperature and stirred overnight. Thesolvent and volatile byproducts may be removed in vacuo. To a solutionof the diaryl phosphorous-containing product, SOCl₂ (excess) may beadded at 0° C. The mixture may be allowed to warm up to room temperatureor heated to 40° C. and may be stirred for an additional day. Thesolvent may then be removed in vacuo, and the residue may be distilledto give the product.

Thus, FIGS. 11A and 11B illustrate alternative processes of forming aphosphonate-based FR molecule that is functionalized with one moiety forcross-linking and one chloride for further bonding with a caprolactonemolecule that is functionalized with one or more hydroxyl groups. WhileFIGS. 11A and 11B illustrate an example in which the phosphonate-basedFR molecule includes a phenyl group, it will be appreciated that thephenyl group may be substituted by ethyl, methyl, propyl, or isopropylgroups, among other alternatives.

FIG. 12 is a chemical reaction diagram 1200 showing a process of forminga FR-functionalized caprolactone molecule with one or more cross-linkersfrom a caprolactone molecule that is functionalized with aphosphonate-based FR molecule that includes an allyl group, according toone embodiment.

In FIG. 12, the letter Y is used to represent a hydroxyl group, an aminegroup, a carboxylic acid group, or an ester group. FIG. 12 illustratesthat the allyl-functionalized caprolactone molecule (formed according toone of the processes described herein with respect to FIGS. 11A and 11B)may be chemically reacted with a molecule that includes a thiol groupand the Y group via thiol-ene “Click” chemistry to form aFR-functionalized caprolactone molecule that includes a hydroxylcross-linker, an amine cross-linker, a carboxylic acid cross-linker, oran ester cross-linker.

As a prophetic example, the thiol compound may be mixed with thevinyl-functionalized FR-functionalized caprolactone. The mixture mayinclude a radical initiator, such as a Micheler's ketone, analpha-amino-ketone, an alpha-hydroxy-ketone, a benzyldimethyl ketal, orbenzophenone (among other alternatives). The reactants may be dissolvedin a solvent such as DCM, benzene, or carbon tetrachloride and reactedunder UV light at a time and temperature suitable to the includedradical initiators as appropriate for desired applications.

Referring to FIG. 13, a chemical reaction diagram 1300 illustrates anexample of a process of forming a third phosphorus-based FR molecule forformation of a FR-functionalized caprolactone molecule, according to oneembodiment. FIG. 13 illustrates that the third phosphorus-based FRmolecule may be synthesized from the renewable furan moiety, furfurylalcohol.

FIG. 13 illustrates an example of a process of forming adifuran-functionalized phosphate molecule from furfuryl alcohol. In thefirst chemical reaction depicted in FIG. 13, furfuryl alcohol ischemically reacted with phosphorus trichloride (PCl₃) to form aphosphine oxide intermediate material. As an example, the first chemicalreaction may include dissolving phosphorus oxychloride in a suitablesolvent, such as dichloromethane (DCM), with the reaction proceedingfrom 0° C. to room temperature. As a prophetic example, phosphorustrichloride and DCM may be placed in a flask immersed in an ice bath andequipped with a magnetic stirrer and a condenser (the head of which isconnected to a water vacuum pump). Furfuryl alcohol, diluted with DCMmay be added dropwise to the mixture. The mixture may be stirred foranother 10 minutes, and DCM may be subsequently evaporated.

As a prophetic example, PCl₃ (1.0 eq.) and freshly dried toluene may beadded to a two-necked round-bottom flask flushed with inert gas. Thereaction mixture may be stirred at 0° C. Furfuryl alcohol (2.0 eq.),dimethylphenylamine (2.16 eq.), and toluene may be added to a separatetwo-necked round-bottom flask flushed with inert gas. The furfurylalcohol mixture may be added dropwise to the PCl₃ solution over 1 hour.The resulting mixture may be stirred at ambient temperature for 1additional hour. Upon completion, water may be added carefully and themixture may be stirred for 30 min at ambient temperature. The crudeproduct may be extracted with Et₂O (2×) and washed with water (2×). Theorganic phase may be dried (MgSO₄) and the solvent may be removed invacuo, and may be dried or purified further.

In the second chemical reaction depicted in FIG. 13, the phosphine oxideintermediate material is chemically reacted with either isocyanuricchloride or tert-butyl hypochlorite (tBuOCl) to formbis(furylmethylene)phosphoryl chloride. In the case of isocyanuricchloride, the second chemical reaction may include a suitable solventsuch as acetonitrile (MeCN). In the case of tert-butyl hypochlorite, thesecond chemical reaction may include a suitable solvent such as DCM.FIG. 13 illustrates that the resulting molecule has a functionalphosphorus group with two furan groups available for subsequentreversible cross-linking.

As a prophetic example (using isocyanuric chloride),bis(furan-2-ylmethyl) phosphite (1.0 eq.) in either dry acetonitrile(MeCN), toluene, or dichloromethane (DCM) may be added to a solution oftrichloroisocyanuric acid (0.33 eq.), N-chlorosuccinimide (1.0 eq.), ortert-butyl hypochlorite (1.0 eq.) in the same solvent at roomtemperature, under an N₂ atmosphere. Upon the formation of aprecipitate, the reaction may be stirred at room temperature for anadditional 2 hours. Upon completion of the reaction, as determined by³¹P NMR, the reaction mixture was passed through a 0.45 μm Whatmansyringe filter and concentrated under vacuum. A similar procedure may beutilized in the case of tert-butyl hypochlorite.

Thus, FIG. 13 illustrates an example of a process of forming aphosphorus-based flame retardant molecule from renewable furfurylalcohol. In the example of FIG. 13, furfuryl alcohol is used to form afuran-containing FR molecule having two furan moieties bonded to aphosphorus moiety via two phosphoryl linkages. As described furtherherein, the phosphorus moiety includes a chloride group for bonding(e.g., via chemical reaction with a hydroxyl group), and the two furanmoieties provide two potential locations for Diels-Alder reactions withdieonophile group(s) of another material.

FIGS. 14A and 14B are chemical reaction diagrams showing alternativeembodiments of processes of forming a fourth phosphorus-based FRmolecule. Referring to FIG. 14A, a first chemical reaction diagram 1400illustrates a first embodiment of a process of forming the fourthphosphorus-based FR molecule. Referring to FIG. 14B, a second chemicalreaction diagram 1410 illustrates an alternative embodiment of a processof forming the fourth phosphorus-based FR molecule.

FIG. 14A illustrates a first example of a process of forming abisfuran-functionalized phosphine oxide molecule. In the first chemicalreaction depicted in FIG. 14A, furfuryl alcohol is chemically reactedwith thionyl chloride to form 2-(chloromethyl)furan, and the chemicalreaction may be performed from 0° C. to room temperature. Alternatively,bromomethylfuran can be synthesized from commercially available reagentsand can be used similarly to chloromethylfuran. In the second chemicalreaction depicted in FIG. 14A, a Grignard reagent is prepared andreacted with the appropriate phosphonic acid diester to form aphosphinic acid intermediate material. In the third chemical reaction ofFIG. 14A, the phosphinic acid intermediate material is reacted withthionyl chloride, resulting in the fourth phosphorus-based FR molecule.

As a prophetic example, furfuryl alcohol may be added, dropwise, to anexcess of thionyl chloride at 0° C. The reaction mixture may be warmedto ambient temperature or reflux and stirred until completion asindicated by TLC. The excess thionyl chloride may be removed in vacuoand the crude product may be used in the next step without furtherpurification. To a stirred suspension of activated magnesium turnings indiethyl ether 2-chloromethylfuran may be added dropwise at 0° C. Uponcompletion of the addition, the reaction mixture may be heated to refluxfor 1 hour. The reaction mixture is then cooled to room temperature andmay be added via cannula to a stirred solution of phosphonic aciddiethyl ester at 0° C. The reaction mixture may be warmed to roomtemperature and stirred until completion, poured into water, andextracted with diethyl ether. The combined organic fractions may bedried over MgSO₄, filtered, and the solvents removed in vacuo. Theproduct may be purified by distillation or recrystallization. Thephosphine oxide product may be added to a suspension of PhIO in anorganic solvent that may include THF or toluene. The reaction mixturemay be stirred for 20 minutes to 12 hours at reflux. The reactionmixture may then be diluted with ether and extracted of 5% NaHCO₃ watersolution. The organic layer may be dried over MgSO₄, evaporated andseparated by chromatography. The water layer may be acidified with conc.HCl and extracted with ether. The combined ether solutions may be driedover MgSO₄, filtered and evaporated to yield the product. Thebis(methyl)furan phosphine oxide may be added, dropwise, to an excess ofthionyl chloride (or oxalyl chloride, or isocyanuric chloride) at 0° C.The reaction mixture may be warmed to ambient temperature or reflux andstirred until completion as indicated by TLC. The excess thionylchloride may be removed in vacuo and the crude product may be purifiedby fractional distillation.

FIG. 14B illustrates a second example of a process of forming thebisfuran-functionalized phosphine oxide molecule. In the first chemicalreaction depicted in FIG. 14B, furfuryl alcohol is chemically reactedwith thionyl chloride to form 2-(chloromethyl)furan, and the chemicalreaction may be performed from 0° C. to room temperature. Alternatively,bromomethylfuran can be synthesized from commercially available reagentsand can be used similarly to chloromethylfuran. In the second chemicalreaction depicted in FIG. 14B, the 2-(chloromethyl)furan product formedfrom the furfuryl alcohol may be used to form a phosphinic esterintermediate material. The third chemical reaction of FIG. 14Billustrates that the phosphinic ester intermediate material is reactedwith phosphorus pentachloride (PCl₅), resulting in the fourthphosphorus-based FR molecule.

As a prophetic example, to a stirred suspension of activated magnesiumturnings in diethyl ether 2-chloromethylfuran (synthesized as describedpreviously) may be added dropwise at 0° C. Upon completion of theaddition, the reaction mixture may be heated to reflux for 1 hour. Thereaction mixture is then cooled to room temperature and may be added viacannula to a stirred solution of phosphonic acid diethyl ester at 0° C.The reaction mixture may be warmed to room temperature and stirred untilcompletion, poured into water, and extracted with diethyl ether. Thecombined organic fractions may be dried over MgSO₄, filtered, and thesolvents removed in vacuo. The product may be purified by distillationor recrystallization. The phosphinic acid product may be stirred with asuspension of potassium carbonate in an organic solvent such as DMF orTHF and heated to a temperature that may be between 60-100° C. Methyliodide and 18-crown-6 may be added dropwise to the reaction mixture, andmay be stirred until completion. The reaction mixture may be poured intowater, and extracted with diethyl ether. The combined organic fractionsmay be dried over MgSO₄, filtered, and the solvents removed in vacuo.The product may be purified by distillation or recrystallization. To asolution of the product from the previous step in CCl₄ may be added PCl₅(excess) at 0° C. under an inert atmosphere. The mixture may be allowedto warm up to room temperature and may be stirred for an additional day.The solvent is removed in vacuo and the residue may be distilled to givethe product.

Thus, FIGS. 14A and 14B illustrate alternative processes of forming afuran-containing flame retardant molecule from renewable furfurylalcohol. In the examples of FIGS. 14A and 14B, furfuryl alcohol is usedto form a furan-containing FR molecule having two furan moieties bondedto a phosphorus moiety via two phosphinyl linkages. As described furtherherein, the phosphorus moiety includes a chloride group for bonding(e.g., via chemical reaction with a hydroxyl group), and the two furanmoieties provide two potential locations for Diels-Alder reactions withdienophile group(s) of another material.

FIGS. 15A and 15B are chemical reaction diagrams showing alternativeembodiments of processes of forming a fifth phosphorus-based FRmolecule. Referring to FIG. 15A, a first chemical reaction diagram 1500illustrates a first embodiment of a process of forming the fifthphosphorus-based FR molecule. Referring to FIG. 15B, a second chemicalreaction diagram 1510 illustrates an alternative embodiment of a processof forming the fifth phosphorus-based FR molecule.

FIG. 15A illustrates a first example of a process of forming amonofuran-functionalized phosphonate molecule. FIG. 15A illustrates aone-step process via reaction of furfuryl alcohol with dichlorophosphatevia careful addition and stoichiometric control. The alkyl (R) groupsmay include ethyl groups, methyl groups, propyl groups, isopropylgroups, or phenyl groups, among other alternatives. The one-step processmay utilize triethylamine (Et₃N) and a suitable solvent, such astetrahydrofuran (THF), and the chemical reaction may be performed from0° C. to room temperature. FIG. 15A illustrates that the resultingmolecule is functionalized with one furan moiety for cross-linking andone chloride for further bonding.

As a prophetic example, to a stirred solution that may include furfurylalcohol (1.0 eq.) and triethylamine (2.0 eq.) in anhydrous THF, phenyldichlorophosphate (1.3 eq.) may be added dropwise at 0° C., and thereaction mixture may be stirred at ambient temperature for 2 hours or itmay be heated up to reflux (60-65° C.) for an extended reaction time (4hours). The reaction mixture may be cooled to ambient temperature andfiltered to remove the triethylamine hydrochloride salt. The solvents ofthe filtrate may be removed in vacuo and the product may be purified byfractional distillation.

FIG. 15B illustrates a second example of a process of forming themonofuran-functionalized phosphate molecule. FIG. 15B illustrates analternative in which furfuryl alcohol can be reacted with titanium (IV)isopropoxide and phosphonic acid dialkylester or diphenylester as apseudotransesterification. The R groups may include ethyl groups, methylgroups, propyl groups, isopropyl groups, or phenyl groups, among otheralternatives. The resulting molecule may be reacted with thionylchloride to give a furan-containing FR molecule with one furan moietyfor cross-linking and one chloride for further bonding. In the firstchemical reaction, titanium (IV) isopropoxide may be dissolved in asuitable solvent, such as benzene. In the second chemical reaction,thionyl chloride may be dissolved in a suitable solvent, such as carbontetrachloride (CCl₄), and the chemical reaction may be performed from 0°C. to room temperature.

As a prophetic example, dialkyl or diaryl phosphite 1 (5.5 mmol) may beadded to the solution of the titanium (IV) isopropoxide (11 mmol) infurfuryl alcohol (excess). This solution may be diluted with benzene.The reaction mixture may be heated 40° C. until completion. The mixturemay be poured into water, extracted with CH₂Cl₂ (3×), dried over MgSO₄,and solvent and volatile components may be removed in vacuo. Theproducts may be purified by fractional distillation orrecrystallization. The product from the first step (1.0 eq.), in dryacetonitrile (MeCN), toluene, or dichloromethane (DCM), may be added toa solution of trichloroisocyanuric acid (0.33 eq.), N-chlorosuccinimide(1.0 eq.), or tert-butyl hypochlorite (1.0 eq.) in the same solvent atroom temperature, under an N₂ atmosphere. Upon the formation of aprecipitate, the reaction may be stirred at room temperature for anadditional 2 hours. Upon completion of the reaction, as determined by³¹P NMR, the reaction mixture may be passed through a 0.45 μm Whatmansyringe filter and concentrated under vacuum.

Thus, FIGS. 15A and 15B illustrate examples of alternative processes offorming the fifth phosphorus-based FR molecule. In the examples of FIGS.15A and 15B, furfuryl alcohol is used to form a furan-containing FRmolecule having a single furan moiety bonded to a phosphorus moiety viaa phosphoryl linkage. As described further herein, the phosphorus moietyincludes a chloride group for bonding (e.g., via chemical reaction witha hydroxyl group), and the single furan moiety provides one potentiallocation for a Diels-Alder reaction with a dienophile group of anothermaterial.

FIGS. 16A and 16B are chemical reaction diagrams showing alternativeembodiments of processes of forming a sixth phosphorus-based FRmolecule. Referring to FIG. 16A, a first chemical reaction diagram 1600illustrates a first embodiment of a process of forming the sixthphosphorus-based FR molecule. Referring to FIG. 16B, a second chemicalreaction diagram 1610 illustrates an alternative embodiment of a processof forming the sixth phosphorus-based FR molecule.

FIG. 16A illustrates a first example of a process of forming the singlephosphonate-linked furan phosphoryl chloride, methylenefuran-phosphonylchloride. In the first chemical reaction depicted in FIG. 16A,2-(chloromethyl)furan (which may be synthesized as described herein withrespect to the fourth phosphorus-based FR molecule of FIGS. 14A and 14B)is chemically reacted with a trialkylphosphite or a triphenylphosphiteto form a phosphonyl ester. R groups may include ethyl groups, methylgroups, propyl groups, isopropyl groups, or phenyl groups, among otheralternatives. In the second chemical reaction depicted in FIG. 16A, thephosphonyl ester is reacted with phosphorus pentachloride to form thesixth phosphorus-based FR molecule.

As a prophetic example, 2-(chloromethyl)furan (1 eq.) and trialkylphosphite may be added to a reaction vessel, which may include anorganic solvent such as toluene, THF, ethanol, or DMF, and may alsocontain a compound such an alumina. The reaction may be heated to refluxor up to 180° C. if done using neat conditions. The reaction mixture mayalso be irradiated by microwaves for a short period to increase thereaction rate. The reaction may be cooled to room temperature and theexcess trialkyl phosphite may be removed in vacuo or it may be washedwith DCM, and dried for CaCl₂ prior to filtration and having thesolvents removed in vacuo. The phosphonate may be purified by fractionaldistillation. To a solution of the phosphonate product PCl₅ (excess) maybe added at 0° C. under an inert atmosphere. The reaction may beperformed in a solvent such as CCl₄. The mixture may be allowed to warmup to room temperature and may be stirred for an additional day. Thesolvent is then removed in vacuo and the residue may be distilled togive the product.

FIG. 16B illustrates a second example of a process of forming the singlephosphonate-linked furan phosphoryl chloride, methylenefuran-phosphonylchloride. In the first chemical reaction depicted in FIG. 16B,2-(chloromethyl)furan (synthesized as described herein with respect toFR7) is reacted with a trialkylphosphite or a triphenylphosphite andquenched under aqueous basic conditions to form an alternativeintermediate material. R groups may include ethyl groups, methyl groups,propyl groups, isopropyl groups, or phenyl groups, among otheralternatives. The second chemical reaction of FIG. 16B illustrates thatthe intermediate material is then reacted with thionyl chloride to formthe sixth phosphorus-based FR molecule.

As a prophetic example, a methylfuryl phosphonate may be generated in amanner similar to that of the phosphonate intermediate used tosynthesize the fourth furan-containing FR molecule. Dialkylbenzylphosphonate (1.0 eq.) may be quickly added to a solution ofbromodimethyl borane (1.0 eq.) in an organic solvent that may betoluene. The reaction mixture may be warmed to room temperature andstirred overnight. The solvent and volatile byproducts may be removed invacuo and give a slightly yellow viscous oil. To a solution of thephosphonic acid product SOCl₂ (excess) may be added at 0° C. The mixturemay be allowed to warm up to room temperature, or heated to 40° C. andmay be stirred for an additional day. The solvent is then removed invacuo and the residue may be distilled to give the product.

Thus, FIGS. 16A and 16B illustrate alternative processes of forming afuran-containing FR molecule from renewable furfuryl alcohol. In theexamples of FIGS. 16A and 16B, furfuryl alcohol is used to form afuran-containing FR molecule having a single furan moiety bonded to aphosphorus moiety via a phosphinyl linkage. As described further herein,the phosphorus moiety includes a chloride group for bonding (e.g., viachemical reaction with a hydroxyl group), and the single furan moietyprovides one potential location for a Diels-Alder reaction with adienophile group of another material.

Referring to FIG. 17, a flow diagram 1700 illustrates an example of aprocess of forming a flame retardant polycaprolactone. In the example ofFIG. 17, a hydroxyl-functionalized caprolactone molecule is chemicallyreacted with a phosphorus-containing flame retardant molecule to form aflame retardant-functionalized caprolactone monomer. In some cases, theflame retardant polycaprolactone is formed by polymerizing the flameretardant-functionalized caprolactone monomer. In other cases, a mixtureof the flame retardant-functionalized caprolactone monomer and anunfunctionalized caprolactone monomer may be polymerized to form a flameretardant polycaprolactone copolymer. It will be appreciated that theoperations shown in FIG. 17 are for illustrative purposes only and thatthe operations may be performed in alternative orders, at alternativetimes, by a single entity or by multiple entities, or a combinationthereof. For example, one entity may form the phosphorus-containingflame retardant molecule, another entity may form thehydroxyl-functionalized caprolactone molecule, while yet another entitymay form the flame retardant-functionalized caprolactone monomer.Additionally, in some cases, another entity may form the flame retardantpolycaprolactone.

The process 1700 includes utilizing a caprolactone molecule to form ahydroxyl-functionalized caprolactone molecule, at 1702. For example, thehydroxyl-functionalized caprolactone molecule may be formed from acaprolactone molecule according to processes previously described hereinwith respect to FIGS. 1, 2, 5, and 6. In the example depicted in FIG. 1,the hydroxyl-functionalized caprolactone molecule includes two hydroxylgroups. In the example depicted in FIG. 2, the hydroxyl-functionalizedcaprolactone molecule includes four hydroxyl groups. In the exampledepicted in FIG. 5, the hydroxyl-functionalized caprolactone moleculeincludes one hydroxyl group. In the example depicted in FIG. 6, thehydroxyl-functionalized caprolactone molecule includes two hydroxylgroups. In some cases, the reaction conditions may result in a mixtureof stereochemistry, in which the hydroxyl-functionalized caprolactonemolecule includes both 3,4-hydroxyl-caprolactone and3,5-hydroxyl-caprolactone, each of which have two hydroxyl groups permolecule.

The process 1700 includes chemically reacting thehydroxyl-functionalized caprolactone molecule with aphosphorus-containing flame retardant molecule to form a flameretardant-functionalized caprolactone molecule, at 1704. For example,the hydroxyl-functionalized caprolactone molecule may be chemicallyreacted with one of the phosphorus-based flame retardant molecules ofthe present disclosure, according to processes previously describedherein with respect to FIGS. 1, 2, 5, and 6. In some cases, thephosphorus-based flame retardant molecule that is chemically reactedwith the hydroxyl-functionalized caprolactone molecule may correspond tothe first phosphorus-based flame retardant molecule described hereinwith respect to FIGS. 9A and 9B. In other cases, the phosphorus-basedflame retardant molecule may correspond to the second phosphorus-basedflame retardant molecule described herein with respect to FIGS. 11A and11B. In other cases, the phosphorus-based flame retardant molecule maycorrespond to the third phosphorus-based flame retardant moleculedescribed herein with respect to FIG. 12. In other cases, thephosphorus-based flame retardant molecule may correspond to the fourthphosphorus-based flame retardant molecule described herein with respectto FIGS. 14A and 14B. In other cases, the phosphorus-based flameretardant molecule may correspond to the fifth phosphorus-based flameretardant molecule described herein with respect to FIGS. 15A and 15B.In other cases, the phosphorus-based flame retardant molecule maycorrespond to the sixth phosphorus-based flame retardant moleculedescribed herein with respect to FIGS. 16A and 16B.

The process 1700 includes polymerizing a mixture that includes at leastthe flame retardant-functionalized caprolactone monomer to form a flameretardant polycaprolactone, at 1706. For example, referring to FIG. 1,the first flame retardant polycaprolactone may be formed from the firstflame retardant-functionalized caprolactone monomer. As another example,referring to FIG. 2, the second flame retardant polycaprolactone may beformed from the second flame retardant-functionalized caprolactonemonomer. As a further example, referring to FIG. 5, the third flameretardant polycaprolactone may be formed from the third flameretardant-functionalized caprolactone monomer. As yet another example,referring to FIG. 6, the fourth flame retardant polycaprolactone may beformed from the fourth flame retardant-functionalized caprolactonemonomer.

In some cases, the mixture may further include an unfunctionalizedcaprolactone monomer, and the flame retardant polycaprolactone maycorrespond to a flame retardant polycaprolactone copolymer. For example,referring to FIG. 3, the first flame retardant polycaprolactonecopolymer may be formed from a mixture that includes an unfunctionalizedcaprolactone monomer and the first flame retardant-functionalizedcaprolactone monomer of FIG. 1. As another example, referring to FIG. 4,the second flame retardant polycaprolactone copolymer may be formed froma mixture that includes an unfunctionalized caprolactone monomer and thesecond flame retardant-functionalized caprolactone monomer of FIG. 2. Asa further example, referring to FIG. 7, the third flame retardantpolycaprolactone copolymer may be formed from a mixture that includes anunfunctionalized caprolactone monomer and the third flameretardant-functionalized caprolactone monomer of FIG. 5. As yet anotherexample, referring to FIG. 8, the fourth flame retardantpolycaprolactone copolymer may be formed from a mixture that includes anunfunctionalized caprolactone monomer and the fourth flameretardant-functionalized caprolactone monomer of FIG. 6.

Thus, FIG. 17 illustrates an example of a process of forming a flameretardant polycaprolactone. In the example of FIG. 17, ahydroxyl-functionalized caprolactone molecule is chemically reacted witha phosphorus-containing flame retardant molecule to form a flameretardant-functionalized caprolactone monomer. In some cases, the flameretardant polycaprolactone is formed by polymerizing the flameretardant-functionalized caprolactone monomer. In other cases, a mixtureof the flame retardant-functionalized caprolactone monomer and anunfunctionalized caprolactone monomer may be polymerized to form a flameretardant polycaprolactone copolymer.

Referring to FIG. 18, a flow diagram 1800 illustrates an example of aprocess of forming a flame retardant polycaprolactone. In the example ofFIG. 18, a hydroxyl-functionalized caprolactone molecule is chemicallyreacted with a phosphorus-containing flame retardant molecule (thatincludes an allyl group) to form a flame retardant-functionalizedcaprolactone monomer (that includes the allyl group). Subsequently, theflame retardant-functionalized caprolactone monomer (that includes theallyl group) is chemically reacted with a thiol (that includes across-linking moiety) to form an FR-functionalized caprolactone monomer(that includes the cross-linking moiety). In some cases, the flameretardant polycaprolactone is formed by polymerizing the flameretardant-functionalized caprolactone monomer (that includes thecross-linking moiety). In other cases, a mixture of the flameretardant-functionalized caprolactone monomer (that includes thecross-linking moiety) and an unfunctionalized caprolactone monomer maybe polymerized to form a flame retardant polycaprolactone copolymer. Itwill be appreciated that the operations shown in FIG. 18 are forillustrative purposes only and that the operations may be performed inalternative orders, at alternative times, by a single entity or bymultiple entities, or a combination thereof.

The process 1800 includes utilizing a caprolactone molecule to form ahydroxyl-functionalized caprolactone molecule, at 1802. For example, thehydroxyl-functionalized caprolactone molecule may be formed from acaprolactone molecule according to processes previously described hereinwith respect to FIGS. 1, 2, 5, and 6.

The process 1800 includes chemically reacting thehydroxyl-functionalized caprolactone molecule with aphosphorus-containing flame retardant molecule that includes an allylgroup to form a flame retardant-functionalized caprolactone moleculethat includes the allyl group, at 1804. For example, referring to FIGS.9A and 9B, when the alcohol (ROH) is allyl alcohol, the firstphosphorus-based flame retardant molecule includes an allyl group. Inthis case, referring to FIG. 10, the allyl group of the firstphosphorus-based flame retardant molecule of FIGS. 9A and 9B may bechemically reacted with one of the FR-functionalized caprolactonemolecules formed according to processes previously described herein withrespect to FIGS. 1, 2, 5, and 6. FIG. 10 illustrates that the resultingFR-functionalized caprolactone molecule includes the allyl group. Asanother example, referring to FIGS. 11A and 11B, when the chloride (RCl)is allyl chloride, the second phosphorus-based flame retardant moleculeincludes an allyl group. In this case, referring to FIG. 12, the allylgroup of the second phosphorus-based flame retardant molecule of FIGS.11A and 11B may be chemically reacted with one of the FR-functionalizedcaprolactone molecules formed according to processes previouslydescribed herein with respect to FIGS. 1, 2, 5, and 6. FIG. 12illustrates that the resulting FR-functionalized caprolactone moleculeincludes the allyl group.

The process 1800 includes chemically reacting the allyl group of theflame retardant caprolactone molecule with a thiol (that includes across-linking moiety) to form a flame retardant-functionalizedcaprolactone monomer that includes the cross-linking moiety (1806). Forexample, referring to FIG. 10, the FR-functionalized caprolactonemolecule that includes the allyl group may be chemically reacted with athiol (that includes a hydroxyl group, an amine group, a carboxyl group,or an ester group) via thiol-ene “Click” chemistry to form theFR-functionalized caprolactone molecule with cross-linker(s). As anotherexample, referring to FIG. 12, the FR-functionalized caprolactonemolecule that includes the allyl group may be chemically reacted with athiol (that includes a hydroxyl group, an amine group, a carboxyl group,or an ester group) via thiol-ene “Click” chemistry to form theFR-functionalized caprolactone molecule with cross-linker(s).

The process 1800 further includes polymerizing a mixture that includesat least the flame retardant-functionalized caprolactone monomer to forma flame retardant polycaprolactone, at 1808. For example, referring toFIG. 1, the first flame retardant polycaprolactone may be formed fromthe first flame retardant-functionalized caprolactone monomer (thatcorresponds to the FR-functionalized caprolactone molecule depicted inFIG. 10 or FIG. 12). As another example, referring to FIG. 2, the secondflame retardant polycaprolactone may be formed from the second flameretardant-functionalized caprolactone monomer (that corresponds to theFR-functionalized caprolactone molecule depicted in FIG. 10 or FIG. 12).As a further example, referring to FIG. 5, the third flame retardantpolycaprolactone may be formed from the third flameretardant-functionalized caprolactone monomer (that corresponds to theFR-functionalized caprolactone molecule depicted in FIG. 10 or FIG. 12).As yet another example, referring to FIG. 6, the fourth flame retardantpolycaprolactone may be formed from the fourth flameretardant-functionalized caprolactone monomer (that corresponds to theFR-functionalized caprolactone molecule depicted in FIG. 10 or FIG. 12).

In some cases, the mixture may further include an unfunctionalizedcaprolactone monomer, and the flame retardant polycaprolactone maycorrespond to a flame retardant polycaprolactone copolymer. For example,referring to FIG. 3, the first flame retardant polycaprolactonecopolymer may be formed from a mixture that includes an unfunctionalizedcaprolactone monomer and the first flame retardant-functionalizedcaprolactone monomer of FIG. 1 (that corresponds to theFR-functionalized caprolactone molecule depicted in FIG. 10 or FIG. 12).As another example, referring to FIG. 4, the second flame retardantpolycaprolactone copolymer may be formed from a mixture that includes anunfunctionalized caprolactone monomer and the second flameretardant-functionalized caprolactone monomer of FIG. 2 (thatcorresponds to the FR-functionalized caprolactone molecule depicted inFIG. 10 or FIG. 12). As a further example, referring to FIG. 7, thethird flame retardant polycaprolactone copolymer may be formed from amixture that includes an unfunctionalized caprolactone monomer and thethird flame retardant-functionalized caprolactone monomer of FIG. 5(that corresponds to the FR-functionalized caprolactone moleculedepicted in FIG. 10 or FIG. 12). As yet another example, referring toFIG. 8, the fourth flame retardant polycaprolactone copolymer may beformed from a mixture that includes an unfunctionalized caprolactonemonomer and the fourth flame retardant-functionalized caprolactonemonomer of FIG. 6 (that corresponds to the FR-functionalizedcaprolactone molecule depicted in FIG. 10 or FIG. 12).

Thus, FIG. 18 illustrates an example of a process of forming a flameretardant polycaprolactone. In the example of FIG. 18, In the example ofFIG. 18, a hydroxyl-functionalized caprolactone molecule is chemicallyreacted with a phosphorus-containing flame retardant molecule (thatincludes an allyl group) to form a flame retardant-functionalizedcaprolactone monomer (that includes the allyl group). Subsequently, theflame retardant-functionalized caprolactone monomer (that includes theallyl group) is chemically reacted with a thiol (that includes across-linking moiety) to form an FR-functionalized caprolactone monomer(that includes the cross-linking moiety). In some cases, the flameretardant polycaprolactone is formed by polymerizing the flameretardant-functionalized caprolactone monomer. In other cases, a mixtureof the flame retardant-functionalized caprolactone monomer and anunfunctionalized caprolactone monomer may be polymerized to form a flameretardant polycaprolactone copolymer.

It will be understood from the foregoing description that modificationsand changes may be made in various embodiments of the present inventionwithout departing from its true spirit. The descriptions in thisspecification are for purposes of illustration only and are not to beconstrued in a limiting sense. The scope of the present invention islimited only by the language of the following claims.

What is claimed is:
 1. A process of forming a flame retardant monomer,the process comprising: forming a hydroxyl-functionalized caprolactonemolecule; and reacting the hydroxyl-functionalized caprolactone moleculewith a phosphorus-containing flame retardant molecule to form a flameretardant functionalized caprolactone monomer.
 2. The process of claim1, further comprising reacting the flame retardant functionalizedcaprolactone monomer with an unfunctionalized caprolactone monomer toform a flame-retardant polycaprolactone copolymer.
 3. The process ofclaim 1, wherein the phosphorus-containing flame retardant moleculeincludes a cross-linking moiety.
 4. The process of claim 3, wherein thecross-linking moiety includes an allyl group, an epoxide group, or afuran group.
 5. The process of claim 3, wherein the cross-linking moietyincludes an allyl group, and wherein the phosphorus-containing flameretardant molecule is formed from allylic alcohol.
 6. The process ofclaim 3, wherein the cross-linking moiety includes an epoxide group, andwherein the phosphorus-containing flame retardant molecule is formedfrom glycidol.
 7. The process of claim 3, wherein the cross-linkingmoiety includes a furan group, and wherein the phosphorus-containingflame retardant molecule is formed from furfuryl alcohol.
 8. The processof claim 3, wherein the cross-linking moiety includes a furan group, andwherein the phosphorus-containing flame retardant molecule is formedfrom 2-(chloromethyl)furan.
 9. A flame retardant monomer, comprising: atleast one moiety derived from a hydroxyl-functionalized caprolactonemolecule; and at least one phosphorus-containing flame retardant moiety.10. The flame retardant monomer of claim 9, wherein thephosphorus-containing flame retardant moiety includes an allyl group.11. The flame retardant monomer of claim 9, wherein thephosphorus-containing flame retardant moiety includes an alkyl group.12. The flame retardant monomer of claim 9, wherein thephosphorus-containing flame retardant moiety includes at least onephenyl group.
 13. The flame retardant monomer of claim 9, wherein thephosphorus-containing flame retardant moiety includes an epoxide group.14. The flame retardant monomer of claim 9, wherein thephosphorus-containing flame retardant moiety includes a thioetherlinking group.
 15. A flame retardant polymer, comprising: at least twoflame retardant monomer repeat units, each flame retardant monomerrepeat unit comprising: at least one moiety derived from ahydroxyl-functionalized caprolactone molecule; and at least onephosphorus-containing flame retardant moiety.
 16. The flame retardantpolymer of claim 15, further comprising at least one unfunctionalizedcaprolactone repeat unit.
 17. The flame retardant polymer of claim 15,wherein the flame retardant polymer is a homopolymer.
 18. The flameretardant polymer of claim 15, wherein the flame retardant polymer is acopolymer.
 19. The flame retardant polymer of claim 15, wherein theflame retardant polymer is formed in a polymerization catalyzed bytin(II) octanoate.
 20. The flame retardant polymer of claim 15, whereinthe flame retardant polymer includes cross-linking bonds.